Process Monitoring
Automated real time monitoring of processes, machines and plants is based on acquired measurement data, camera images and calculated characteristic…
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Aluminum
Sectors
Aluminum production is a highly energy-intensive process, while aluminum rolling is characterized by extremely high process speeds. Both require precise control of complex thermal and mechanical operations. With the iba system, all relevant process and machine data can be acquired synchronously and at high sampling rates. This enables early fault detection, efficient monitoring of energy consumption, and long-term process optimization – ensuring reliable operations and consistently high product quality.
Increase Precision and Product Quality
Precision and consistent quality are essential in aluminum production. The iba system provides complete visibility into all relevant process parameters.
Advanced analysis, monitoring, and visualization capabilities support rapid decision-making, early fault detection, and sustainable optimization of energy consumption and production processes, enabling efficient operations in highly dynamic production environments.
With ibaCapture, individual process steps can be monitored using cameras wherever conventional sensors are unavailable or sensor installation would be too complex. The video streams can be visualized together with measurement data in the control room or analyzed alongside process data in the event of faults. Real-time image evaluation using machine vision algorithms is also possible. This allows information to be extracted directly from video streams and stored like conventional measurement values. Using ibaQDR, time-based process data can be converted into length-related quality data, allowing measurement values to be assigned precisely to every position within a coil. With ibaAnalyzer, coil-related key performance indicators can be calculated easily and flexibly – and with ibaDatCoordinator, even process-synchronously and fully automated. This enables seamless transfer of quality data into databases and supports the implementation of comprehensive reporting systems.
With the iba system, we index all relevant process values, such as furnace data, to an individual slab ID – even when up to 30 products are being processed simultaneously.
Bernard Cavin
Process Engineer, Novelis
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Successful applications and real solutions with the iba system.
Vibration Analysis
For reliable real-time monitoring of vibrations, offline analysis tools for optimization and validation are indispensable. The iba system offers you…
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Quality Control
For documenting the automatically manufactured products, quality data and characteristic values need to be calculated and reliably stored in a quality…
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Process Analysis With ibaCapture: Keep an Eye on the Entire Plant With Process Specific Camera Monitoring
Usually, the operator does not have a free view on all components and aggregates from the control panel of a rolling mill. This is why camera systems…
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Unlocking the Full Potential of Measurement Data: A Value Creation Approach Through Digitalization
Increasing complexity and process speed pose significant challenges for technology-intensive manufacturing companies. Not only do these factors make…
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Long-Term Analysis
The iba system enables continuous acquisition and long-term storage of process and machine data in high temporal resolution. All data is centrally…
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PLC Analysis
Failures in automated systems can lead to production downtime and inferior quality. Failure mode analysis is easily achieved for maintenance personnel…
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Increasing Product Quality by Means of Visual Signals: Online Process Monitoring With ibaVision
The task is to detect rhomboidity during a continuous casting process. This needs to be done to allow timely process adjustments and consequently…
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AI-Powered Coil Strap Detection with ibaVision
In the production of aluminum coils, proper strapping is essential to ensure safe handling and transport.
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Finding a Needle in a Haystack in Seconds: BILSTEIN Monitors Coils With ibaDatawyzer-ICC
Over 1,600 tons of metal, rolled into coils, pass through the BILSTEIN Group’s production facilities every day. To eliminate the risk of mix-ups, the…
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“With ibaHD-Server, we have direct access to seven years of historical data”
What began seven years ago with the replacement of paper chart recorders in a pusher-type furnace has evolved into a key pillar of quality assurance…
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“ibaDaVIS gives all users easy access to the data and helps us resolve emerging issues more quickly.”
As the legacy system no longer met operational demands, the BILSTEIN GROUP had to seek out a new solution for process data visualization. Their…
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A Quick Look at Historical Data
In order to analyze processes efficiently, Neuman Aluminium introduced the iba system in production in 2014. Due to its success, it was rolled out to…
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With a Unified View of All Process Data: Novelis Relies on the iba System
The commissioning of a new pusher type furnace at their Swiss location prompted Novelis to standardize the acquisition and analysis of process data.…
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iba-Based Quality Data Determination: TEAS (Thickness Evaluation and Analysis System) and PEAS (Profile Evaluation and Analysis System) at Aluminium Norf GmbH (Alunorf)
Alunorf is the largest aluminum rolling and smelting plant in the world. Around 1.5 million tons of rolled aluminum strip are shipped from the plant…
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Aluminium Processing Plant: Vibration Monitoring System for Cold Rolling Mills and Tension Leveler
The iba system provides a state-of-the-art condition and vibration monitoring system. Since it had been installed, many critical downtimes have been…
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Detecting Critical Vibrations in Rolling Mills
In a cold rolling mill, the process data recording system ibaPDA has been used for process data analysis, but the vibration measurement data was…
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Digital Process Monitoring in Batch Annealing
From Paper Chart Recorders to Modern Data Acquisition: To ensure reliable analysis and visualization of furnace data, Aluminium Norf relies on the iba…
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Frequently Asked Questions (FAQ)In aluminum production, precise and time-synchronous data acquisition is essential, as both thermal and mechanical processes are highly dynamic. The iba system captures all relevant process and machine data at high frequency and in a synchronized manner, making them centrally available. This creates a reliable data foundation for monitoring energy consumption, process stability, and product quality across the entire production chain.
In high-dynamic rolling processes, combining measurement data with camera images enables a significantly more comprehensive quality analysis. With ibaCapture, visual process information can be captured and synchronized with measurement data, making even hard-to-measure process steps transparent. This combination improves fault detection, supports root cause analysis, and enhances overall process reliability.
By converting time-based measurement data into length-based information, quality parameters can be evaluated precisely along the entire coil. With ibaQDR and the associated analysis tools, process and quality data can be referenced to every position in the material. This creates continuous quality assessment, enabling precise evaluation of material properties across the full coil length.
Historical process data enables sustainable optimization of production processes by revealing patterns, deviations, and correlations over long periods. With ibaDatCoordinator and ibaAnalyzer, this data can be automatically processed, analyzed, and provided for reporting or database systems. This supports continuous improvement and targeted optimization of energy and quality KPIs.
End-to-end traceability is achieved by consistently capturing process, energy, and quality data and clearly assigning them to production objects such as billet or coil IDs. The iba system enables this assignment even when multiple products are processed in parallel and provides the data centrally for analysis and reporting. This creates full transparency across the entire production process.
In aluminum production, precise and time-synchronous data acquisition is essential, as both thermal and mechanical processes are highly dynamic. The iba system captures all relevant process and machine data at high frequency and in a synchronized manner, making them centrally available. This creates a reliable data foundation for monitoring energy consumption, process stability, and product quality across the entire production chain.
In high-dynamic rolling processes, combining measurement data with camera images enables a significantly more comprehensive quality analysis. With ibaCapture, visual process information can be captured and synchronized with measurement data, making even hard-to-measure process steps transparent. This combination improves fault detection, supports root cause analysis, and enhances overall process reliability.
By converting time-based measurement data into length-based information, quality parameters can be evaluated precisely along the entire coil. With ibaQDR and the associated analysis tools, process and quality data can be referenced to every position in the material. This creates continuous quality assessment, enabling precise evaluation of material properties across the full coil length.
Historical process data enables sustainable optimization of production processes by revealing patterns, deviations, and correlations over long periods. With ibaDatCoordinator and ibaAnalyzer, this data can be automatically processed, analyzed, and provided for reporting or database systems. This supports continuous improvement and targeted optimization of energy and quality KPIs.
End-to-end traceability is achieved by consistently capturing process, energy, and quality data and clearly assigning them to production objects such as billet or coil IDs. The iba system enables this assignment even when multiple products are processed in parallel and provides the data centrally for analysis and reporting. This creates full transparency across the entire production process.
